Tick pattern for simulated wood transfer films and method of making same

ABSTRACT

A heat-transferable film and a method for providing a tick pattern on a film-decorated substrate is provided. The heat-transferable film comprises (1) a transfer layer in facing engagement with a substrate having a first gloss level, at least one color, and a heat-activatable adhesive layer; (2) a plurality of individual spaced-apart markings, the markings having a color different from the color or colors within the transfer layer and a second gloss level different from the first gloss level, the markings adhered to the top of the transfer layer; and (3) a carrier sheet adhered to the top of the individual spaced-apart markings. Heat and pressure are applied to the top of the carrier sheet such that the heat-activatable adhesive affixes the heat-transferable film to the substrate. The individual spaced-apart markings are split along a plane generally parallel to that of the film by stripping the carrier sheet from the film, whereby a first portion of the each marking remains adhered to the carrier sheet after removal and a second portion of each marking remains adhered to the transfer layer, the second portion of each marking thereby forming a tick pattern.

FIELD OF THE INVENTION

The present invention relates to simulated wood transfer films and amethod of making the same. More particularly, the invention is directedto the provision of a realistic tick pattern in simulated wood transferfilms.

BACKGROUND OF THE INVENTION

Simulated wood transfer films are used for providing the appearance ofreal wood grain to many surfaces including furniture, countertops,walls, siding and automobiles. In order to enhance the wood-likeappearance of such films, those skilled in the art have employed variousmethods to simulate the texture and grain pattern of real wood. Theroughened texture of natural wood is a result in part of smallindentations or slash marks present throughout the grain pattern knownas tick marks.

Early methods for simulating a natural wood design involved embossing toform a series of depressions in the wood grain pattern provided on filmas described, for example, in U.S. Pat. No. 3,452,861 by Ervin.

U.S. Pat. Nos. 3,666,516, 3,770,479 and 3,953,635 by Dunning utilizedindentations in combination with a change in specular reflectance, i.e.,gloss level, on heat-stamped simulated wood film to improve upon merelyembossed depressions. While improving upon methods of providing ticks bymere indentation, adding a change in gloss level still does not providea sufficiently realistic simulation of a real wood tick pattern, becausethe optical effect is not sufficiently perceived when viewed from anangle perpendicular to the plane of the film. The maximum optical effectfrom such a tick is perceived when viewed at an angle of approximately45° to the plane of the film.

The reason a natural tick can be perceived at varied angles is that inaddition to the actual depression or indentation in the wood surface, acolor is present in the indentation. Thus, the appearance of the opticaleffect of an indentation would be enhanced if the areas of lower glosslevel also possessed coloration.

A simulated wood film is manufactured by providing individual coatingsor layers to a polymer film. Wood patterns are created by providingvarious consecutive ink prints in alignment with one another upon thefilm by gravure roller. The pattern is kept in alignment, orregistration, by varying methods of process control. Manufacturers haveattempted to register a coating providing the optical tick marks and asecond further coating which provides coloration to those marks. Theseattempts have not been successful due to the small size of the marks andthe degree of registration currently attainable by available methods ofprocess control.

One such early attempt is found in U.S. Pat. No. 3,936,570. In thetransfer material described in that patent, gaps are made in a fullyreleasable stripping layer adhered to a carrier sheet. A design coatwhich may cover the entire stripping layer or only the gaps is thencoated on the stripping layer. When the carrier sheet is removed, thestripping layer fully remains on the transferred wood film and a portionof the design layer is torn away with the carrier creating an unevenphysical embossing on the surface of the transferred film. While thedesign layer may optionally contain pigment and provides a change inspecular reflectance, it is unevenly depressed beneath the surface ofthe film and the stripping layer incompletely covers the surface of thefilm.

There is a need in the art for a simulated wood transfer film having atick pattern which more closely resembles that of the indentations inreal wood due to the presence of color and a lower gloss within the tickmarks, but which does not require embossing or gaps in the protectivecovering.

SUMMARY OF THE INVENTION

It has been discovered according to the present invention that byproviding both a different color and a lower gloss level within a singlecoating, an improved optical effect is created without indentation inthe surface of the film and without the need for alignment of twoseparate coatings.

The simulated heat-transferable film according to the present invention,particularly for simulated wood grains, comprises a transfer layer, aplurality of individual spaced-apart markings and a carrier sheet. Thetransfer layer, which is affixable on the bottom to a substrate, has afirst gloss level and at least one color. The plurality of individualspaced-apart markings have a second gloss level, different from thefirst gloss level, and a color different from the color or colors withinthe transfer layer. The individual spaced-apart markings are adhered tothe top of the transfer layer.

The carrier sheet is adhered to the top of the individual spaced-apartmarkings such that upon application of heat and pressure to the film,and subsequent removal of the carrier sheet, the markings are splitalong a plane generally parallel to that of the film. The first portionof each marking remains adhered to the carrier sheet. The second portionof each marking remains adhered to the transfer layer such that thesecond portion of each marking forms a tick pattern on the top of thetransfer layer.

The pigmented, lower gloss tick provides a realistic looking tickpattern. The change in gloss between the surface of the transfer layerand the tick provides an optical effect contributing to the simulationof a real wood tick. The color within the tick layer, combined with thechange in gloss, further enhances that optical effect, providing a morerealistic appearance to the tick markings.

In one embodiment of the invention, the transfer layer comprises severalindividual layers. A heat-activatable adhesive layer on the bottom ofthe transfer layer is provided for affixing to a substrate. A base coatis adhered to the top of the heat-activatable adhesive layer. At leastone print layer comprising an ink pattern is adhered to the top of thebase coat. A protective layer covers and adheres to the top of the printlayer or print layers. This layer also acts as a release layer. Theplurality of individual spaced-apart markings are adhered to the top ofthe protective release layer.

The individual spaced-apart markings that make up the tick layerpreferably comprise a mixture of soluble resins, particles of wax,pigment and fluoropolymer dispersed within the mixture of solubleresins, and a catalyst. The catalyst promotes and acceleratescross-linking reactions between the soluble resin mixture and resinswithin the transfer layer and between the soluble resin mixture and thecarrier sheet. The result of this cross-linking is a strong adherence ofthe markings to both the carrier sheet and the transfer layer.

The present invention also comprises a method for providing a tickpattern on a film-decorated substrate, comprising the steps of applyinga heat-transferable film, as described above, to a substrate such thatthe bottom of the heat-transferable film is in facing engagement withthe substrate and applying heat and pressure to the top of the filmcarrier sheet such that the heat-activatable adhesive within thetransfer layer of the film affixes the heat-transferable film to thesubstrate. The method further comprises the step of splitting theindividual spaced-apart markings along a plane generally parallel tothat of the film by stripping the carrier sheet from the film, whereby,a first portion of each marking remains adhered to the carrier sheetafter removal and a second portion of each marking remains adhered tothe transfer layer, the second portion of each marking thereby forming atick pattern.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention, will be better understood whenread in conjunction with the appended drawings. For the purpose ofillustrating the invention, there are shown in the drawings embodimentsof a heat-transferable film which are presently preferred. It shouldalso be understood, that the invention is not limited to the precisearrangements and instrumentalities shown. In the drawings:

FIG. 1 is a cross-sectional representation of one embodiment of theheat-transferable film.

FIG. 2 is a cross-sectional representation of the embodiment shown inFIG. 1 upon removal of the carrier sheet.

FIG. 3 is a plan view of a typical wood grain pattern.

In the drawings, like numerals are used to indicate like elementsthroughout. For ease and clarity of illustration, individual layers ofthe film 10 are shown as extending transversely from one side of thefilm to the other. However, it should be understood to one skilled inthe art that the individual layers of the film 10 may be partial andsegmented, for example if a gravure roller is used to apply those layerscomprising a wood-grain pattern to the film, the individual layers mayactually comprise only a partial transverse layer within the film 10.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Certain terminology is used in the following description for convenienceonly and is not limiting. The words "lower" and "upper" and "top" and"bottom" designate directions in the drawings to which reference ismade. The terminology includes the words above specifically mentioned,derivatives thereof and words of similar import. In addition, the terms"ticks" and "markings" are used interchangeably and should be given thesame meaning. The invention is described generally in terms of a filmcomprising a wood-grain pattern; however, other patterns and designs maybe substituted for wood-grain as desired without departing from theclaimed invention. The invention is also described in terms of a patterncomprising realistic-looking wood ticks; however, markings provided toother patterns which impart both an optical effect and a change in colorsuch that the markings appear to be indented or raised from the surfaceare also contemplated as within the scope of the claimed invention.

As shown in FIG. 1 and 2, the heat-transferable film 10 according to thepresent invention comprises a transfer layer 12, a plurality ofindividual spaced-apart markings 14 and a removable carrier sheet 16.The film 10 is manufactured by applying the individual spaced-apartmarkings 14 or ticks 14 with a gravure-head roller to the carrier sheet16 in order to create a tick pattern 17 as shown in FIG. 3. The carriersheet 16 is the base of the film from a manufacturing perspective. Thetransfer layer 12 is then applied to the ticks 14 in several consecutivelayers. When applying the film 10 to a substrate 18, the transfer layer12 is placed in facing engagement with the substrate 18. The transferlayer 12 serves as the main body of the film 10. The transfer layer 12is affixable to a substrate 18 by the application of heat and pressure.The latter is known to those skilled in the art as hot-stamping.

The top of the transfer layer 12 adheres to the ticks 14 and serves as aprotective coating for the remainder of the transfer layer 12. Thecarrier sheet 16 also adheres to the ticks 14 by bonding with the resinsused in the tick 14 formulations thereby facilitating the splitting ofthe ticks 14 upon removal of the carrier sheet 16. After the bottom ofthe transfer layer 12 is affixed to the substrate 18, the carrier sheet16 is removed. A portion of each of the ticks 14 remains adhered to thecarrier sheet 16 thereby splitting the ticks 14 along a plane generallyparallel to that of the film 10 as shown in FIG. 2. The portion of theticks 14 which is not adhered to the carrier sheet 16 upon removal,remains on the top of the transfer layer 12 creating a realistic tickpattern. In a typical example, about 10% to about 15% of each tick 14 isremoved with the carrier sheet 16.

As shown in FIG. 1 and 2, the transfer layer 12 is made up of severalindividual layers. The first layer, which functions to affix the film 10to the substrate 18 is a heat-activatable adhesive layer 24. A base coat26 is provided on top of the adhesive layer 24 to provide a base colorto the film 10. The wood-grain pattern is created by providing at leastone, but preferably several print coats 28a, 28b on top of the base coat26. A protective release coat 30 is adhered to the top of the printcoats 28a, 28b, thereby shielding the lower layers of the film 10 fromimpact and other surface damage and protecting the integrity of theticks 14 by preventing migration of unwanted compounds from other layerswithin the film 10. In addition, the protective layer 30 bonds to theticks 14 to facilitate splitting of the ticks 14. The protective releaselayer 30 also allows the transfer film 10 to be easily removed from thecarrier sheet 16 when heat transferred.

Beginning with the substrate 18, and describing the various layers ofthe film in greater detail from the substrate 18 up to the carrier sheet16, it will be understood by those skilled in the art that the substrate18 can be any surface capable of bonding to the film 10 of the presentinvention. Typical substrates 18 include, among others, wood, plastic,metal and ceramic. It is understood by those skilled in the art thatother substrates 18 may be used without departing from the presentinvention.

The adhesive chosen for the adhesive layer 24 to be affixed to thesubstrate 18 should be one which, upon application of heat and pressureto the carrier sheet 16, will strongly adhere to the substrate 18 infull facing engagement, forming a smooth, uniform bond to the substrate18 with little or no edge pull-back. A pressure-sensitive adhesive maybe substituted for a heat-activatable adhesive 24 without departing fromthe present invention. However, such a pressure-sensitive adhesive isnot preferred, as the use of heat helps to soften and fuse the layers ofthe film 10 to promote bonding of the carrier sheet 16 and of theprotective layer 30 to the ticks 14, thereby aiding in effectivesplitting of the ticks 14.

It will be understood by those skilled in the art that the choice of anappropriate adhesive 24 formulation is dependent upon the substrate 18to which the film 10 is to be affixed and suitable adhesives are wellknown in the art. For example, for application to a wood substrate 18, apreferred adhesive layer 24 would be a formulation comprisingpolyacrylate, polyamide and mixtures thereof. The adhesive 24 in such acase preferably comprises polyacrylate and polyamide in a range ofratios from about 1:99 to 99:1 polyacrylate to polyamide. If the film 10is to be applied to a plastic substrate 18, the preferred adhesive layer24 would be a formulation comprising vinyl resins, acrylic resins andmixtures thereof. The adhesive 24 in this case preferably comprisesvinyl resin and acrylic resin in a range of ratios of from about 1:99 to99:1. Alternate adhesives may be used having varying levels of adhesionwithout departing from the present invention. Other examples of suitableadhesives include those comprising polystyrene and chlorinated olefins.

The base coat 26, which functions primarily to provide a base color tothe film 10, is adhered to the top of the heat-activatable adhesivelayer 24. The base coat 26 comprises organic and inorganic pigments,solvent and a resin such as an acrylic resin, a vinyl resin and mixturesthereof. During the curing, i.e., film drying, the organic solvent issubstantially removed by evaporation due to the application of heat. Theacrylic and vinyl resins may be any suitable acrylic or vinyl resin,either synthesized or commercially available, capable of bonding to theadhesive layer 24 and optionally capable of cross-linking to provide aprotective base for the film 10. Preferably, the solvent comprises fromabout 50% to about 70% by weight of the base coat formulation prior todrying. The resin or resin mixture preferably comprises from about 50%to about 90% by weight of the base coat, on a solids basis. The pigmentscomprise from about 10% to about 50% by weight on a solids basis. Thebase coat 26 may be omitted from the film 10 without departing from thepresent invention if a thinner, less durable film 10 is desired for aparticular application. If the base coat 26 is omitted, a base color maybe provided to the film 10 by addition of pigment to the adhesive layer24.

The particular pigments and resins used in the base coat 26 aredependent upon the substrate 18 to which the film is to be affixed andthe base color selected for the particular wood grain pattern to beprovided by the film 10. It is understood by those skilled in the artthat selection of such a base coat 26 pigment varies with the desiredwood-grain appearance as the base coat imparts the base color for arealistic wood pattern. Suitable pigments which may be used in the basecoat 26 of the present film 10 include titanium dioxide, silica, ironoxides, talc, mica, clay, zinc oxide, carbon black, lead chromate,metallic pigments, molybdate orange, calcium carbonate and bariumsulfate.

In the preferred embodiment shown in FIGS. 1 and 2 at least one printcoat 28a, 28b is adhered to the top of the base coat 26. The print coatsare depicted in FIGS. 1 and 2 for the purpose of clarity and ease ofillustration as solid layers. It will be understood by those skilled inthe art that such layers 28a, 28b may be only partial in nature as aresult of the method of application in a layered pattern. The printcoats 28a, 28b comprise various inks applied by a series of gravurerollers. The gravure rollers impart a wood-grain pattern 25 as shown inFIG. 3, to the film 10 by applying varying shades of ink in a layeredand registered manner, resulting in a real wood appearance. Preferablyfrom about 1 to about 5 print layers 28a, 28b are provided (only two areshown in the drawings).

It will be understood by one skilled in the art that a solid colored,textured film may be made without the use of print layers 28a, 28b,without departing from the present invention. The print layers 28a, 28bprimarily function to provide the appearance desired by the individualpracticing the invention. Therefore, an altered pattern or filmappearance having enhanced tick marks is contemplated in practicing thepresent invention. It will also be understood that patterns other thanwood-grain which are enhanced in appearance by addition of an enhancedtick 14 are within the scope of this invention.

A protective layer 30 which may also serve as a release layer is adheredto the top of the print layers 28a, 28b. The protective layer 30comprises a lacquer-based coat which may be derived from eitherthermosetting or thermoplastic resins. In the preferred embodiment, athermoplastic protective layer 30 is provided to the film 10. Thethermoplastic protective layer 30 is comprised of one or morenon-reactive resins. The non-reactive resins comprise thosethermoplastic resins lacking in reactive functionality, i.e., a resinsubstantially free from hydroxyl and carboxyl groups such as those usedin the tick 14 formulation as described in detail below. Preferably, theprotective layer 30 is a clear thermoplastic lacquer such as anon-reactive acrylic resin, a non-reactive vinyl resin or mixtures ofthese resins. It will be understood by those skilled in the art thatother non-reactive thermoplastics may be substituted for or combinedwith the non-reactive vinyl and acrylic resins without departing fromthe present invention.

The reactive resins and catalyst within the ticks 14, as describedbelow, react with the non-reactive resins of the protective layer 30providing intercoat adhesion. The actual mechanism or nature of thisreaction is unknown; however, it is believed that the reaction providespolar and/or chemical cross-linking between the ticks 14 and theprotective layer 30 such that the ticks 14 and the protective layer 30are adhered. The ticks 14 are also adhered to the carrier sheet 16. Thelevel of adhesion derived from the strength of the bonds between thereactive resins in the ticks 14 and those resins within the protectivelayer 30 as well as the level of adhesion derived from the strength ofthe bonds between the carrier sheet 16 and those resins within the ticks14 should each be greater than the level of intermolecular cohesionwithin the ticks 14 to facilitate uniform separation of the ticks 14upon removal of the carrier sheet 16. It will be understood from theabove that the resins of the ticks 14 should be selected so that they donot bond with each other or so that they form bonds of a lesser strengththan the bonds formed between the resins within the ticks 14 and thecarrier sheet and between the resins within the ticks 14 and the resinswithin the protective layer 30.

The protective release layer 30 within the transfer layer 12 ispreferably from about 30% by weight to about 50% by weight solvent, andmore preferably from about 30% to about 40% by weight solvent, prior toheat curing. The release layer 30 further comprises from about 25% toabout 85% by weight non-reactive thermoplastic resin, more preferablyfrom about 30% to about 60% by weight polymethylmethacrylate or asimilar resin. Preferably from about 2% to about 10% by weight on asolids basis, more preferably from about 3% to about 7% by weight, of aslip agent such as wax, silicone, fluoropolymer or other similarcompound known to those skilled in the art should be added to theprotective release layer 30 in order to provide resistance to surfacedamage such as scratches or scuff marks. From about 0.2% to about 5% byweight, and preferably from about 0.2% to about 3.0% by weight of apolar, reactive resin may optionally be included. This resin ispreferably a reactive resin such as a reactive vinyl resin, a reactiveacrylic resin or mixtures of reactive vinyl and acrylic resins, and maybe provided to the protective release layer 30 and in different amountsto provide varying levels of adhesion between the ticks 14 and theprotective release layer 30. In addition, the release layer 30 maycomprise from about 0.5% to about 5% by weight, and preferably fromabout 0.5% to about 1.5% by weight vinyl ethylacetate which functions toprovide flexibility as well as to promote a low level of adhesionbetween the protective release layer 30 and the ticks 14.

Some adhesion and bonding between the protective release layer 30 andthe ticks 14 is necessary in order to successfully split the ticks 14.Therefore, small amounts of reactive resin are added to the releaselayer 30 to enhance tick 14 splitting. The level of adhesion derivedfrom the strength of the bonds between the small amount of reactiveresins within the release layer 30 and those resins within the ticks 14and the level of adhesion derived from the strength of the bonds betweenthe carrier sheet 16 and those resins within the ticks 14 must begreater than the level of intermolecular cohesion within the ticks 14 tosuccessfully split the ticks 14.

The organic solvent used to formulate the release layer 30 will bedependent upon the resins selected. It will be understood to one skilledin the art that the protective release layer 30 formulation itselfdepends upon the resins selected for the ticks 14 as well as the type ofcarrier sheet 16 in order to properly facilitate the splitting of theticks 14 between the protective release layer 30 and the carrier sheet16.

The transfer layer 12 has a first film gloss level. Gloss is ameasurement of the degree of specular reflectance. Typical gloss levelsrange from about 17% for a "super-matte" or flat appearance to about 90%for a glossy, shiny appearance as measured by a Gardner 60° gloss meter.It is understood by one skilled in the art that the gloss level of thetransfer layer 12 is dependent upon the end use for or the desiredappearance of the film 10. In addition, gloss levels lower than 17% maybe provided to the transfer layer 12 as long as the gloss level of thetransfer layer 12 is sufficiently different from that which will beimparted to the ticks 14 as described below. The difference should belarge enough so that the optical effect provided by the color within theticks 14 and the difference in gloss levels is perceived by the humaneye as an indentation or elevation in the surface of the film 10. It ispreferred that the difference between the gloss level of the tick 14 andthe gloss level of the transfer film 12 is at least about 3% for theticks 14 to be sufficiently perceptible.

The ticks 14 which are adhered to the protective layer 30 shouldpreferably have a gloss level, or level of specular reflectance, of fromabout 1.5% to about 8% as measured using a Gardner 60° gloss meter. Thescattering and absorption of light resulting primarily from thedispersed particles within the ticks 14, described below, affects thelevel of gloss within the ticks 14 as does the quantity and color of thedispersed pigment particles. A greater quantity of dispersed pigmentparticles contributes to a lower level of gloss within the ticks 14.Darker dispersed pigment particles will also contribute to lowering thelevel of gloss.

In addition, the degree of gloss within the carrier sheet 16 itself maycontribute to the level of gloss within the top surface of theprotective release layer 30 in the preferred embodiment. A higher glosscarrier sheet 16 provides a higher gloss to the transfer layer 12. Amatte carrier sheet 16 is preferred with the low gloss level ticks 14 ofthe present invention. The carrier 16 preferably has a gloss level offrom about 35% to about 40%. However, good quality films may be madewith higher or lower level gloss carrier sheets 16. It is understood bythose skilled in the art that the range of tick 14 gloss levels mayextend higher than 8% depending upon the surface gloss of the transferlayer 12 without departing from the present invention.

The ticks 14 are formulated from an organic solvent dispersion havingdispersed particles of pigment, wax and fluoropolymer comprising fromabout 35% to about 65% by weight, preferably from about 55% to 65% byweight organic solvent, prior to drying the dispersion. The organicsolvent used is dependent upon those resins to be combined in the tick14 formulation. It will be understood by those skilled in the art whichsolvents are suitable with the various resins selected for use informulating the ticks 14.

The remainder of the tick 14 formulation comprises dispersed particles,a mixture of soluble resins and a catalyst. The soluble resins provide amatrix for the dispersed particles, and also function as a wettingmedium for the pigment particles. These resins when used in variouslayers of the film 10 in addition to the ticks 14 also improveflowability and impart overall hardness and abrasion resistance to thesystem. The soluble resin mixture is comprised of a mixture of one ormore reactive resins and one or more non-reactive resins.

The reactive resin component serves to bond the ticks 14 to the carriersheet 16 and to the protective release layer 30. The reactive resin mayalso have a cross-linking mechanism, effectively preventing unwantedresin absorption or migration from the other layers of the film 10.Unwanted absorption of resin from other layers may result in an unwantedincrease in the gloss level of the ticks 14. In addition, suchabsorption may lead to an inconsistent gloss level for the ticks 14and/or a non-uniform release of the carrier sheet 16 from the film 10.The reactive resins may be any polyester, vinyl or acrylic or othersimilar thermosetting resin with hydroxyl or carboxyl functionality.Alternative reactive resins include epoxy resins cured with aminecompounds.

Preferably the reactive resins include acrylic copolymers andterpolymers and vinyl copolymers and terpolymers. The preferablereactive acrylics are copolymers and terpolymers ofpolymethylmethacrylate. Preferred reactive vinyls include polyvinylchloride solution grade resins, preferably copolymers or terpolymers ofpolyvinyl chloride. An example of a preferred terpolymer is the reactionproduct of a random polymerization of vinyl acetate, vinyl chloride andacrylate.

Preferably the reactive resin component present within the mixture ofsoluble resins comprises resins such as melamine, urea formaldehyde ormixtures of melamine and urea formaldehyde resins. It is understood tothose skilled in the art that any melamine and/or urea formaldehyderesin which can react with the reactive acrylic and/or vinyl resins inthe ticks 14 in the presence of the below-described catalyst may be usedwithout departing from the present invention.

The reactive resins should comprise from about 10% to about 30% byweight on a solids basis, and more preferably, from about 15% to about25% by weight on a solids basis of the ticks 14. The preferred ratio ofreactive acrylic and/or vinyl polymer to melamine and/or urea resinwithin the ticks 14 is from about 0.5:1 to about 8:1, and morepreferably is from about 1:1 to 1.6:1.

Suitable acid catalysts for use in the ticks 14 are those which promoteor accelerate cross-linking reactions at lower temperatures between thereactive resins within the ticks 14 and the reactive resins present inthe protective layer 30 as well as cross-linking reactions between thereactive resins within the ticks 14 and the carrier sheet 16. Thesecross-linking reactions create cross-linked polymer structures at theareas of interface between the ticks 14 and the protective layer 30 andthe ticks 14 and the carrier sheet 16 such that the ticks are stronglybonded to the surrounding layers at these interface areas. The result isthat upon removal of the carrier sheet 16, the ticks 14 will readilySplit due to a lower level of intermolecular bond strength or cohesionbetween the molecules within the ticks 14 than is present within thebonds created at the interfacial areas.

Typical suitable catalysts for use in such crosslinking reactionsinclude such materials as organic, sulfonic or mineral acids andmixtures thereof, such as sulfuric acid, p-toluene sulfonic acid or anamine-block acid such as pyridine. A blocked acid catalyst may also beused; however, the reaction rate may be reduced. The ticks 14 preferablycomprise from about 0.2% to about 3% by weight of catalyst on a solidsbasis.

The non-reactive resins are any thermoplastic resins substantially freeof carboxyl or hydroxyl functionality. The non-reactive resin componentimproves pigment wetting.

The dispersed particles in the ticks 14 are comprised of fluoropolymer,wax and pigment. The fluoropolymer may be a homopolymer, copolymer orterpolymer of polyvinylidene fluoride, polyvinylidene chloride,polyvinyl fluoride, polyvinyl chloride, and polychlorotrifluoroethylene;a copolymer of tetrafluoroethylene and hexafluoropropylene; or acopolymer of vinylidene fluoride and hexafluoropropylene. Preferably,the fluoropolymer is a polyvinylidene fluoride homopolymer. The particlesize of the fluoropolymer should preferably be from about 0.2 to about 5microns. Dispersed particles of fluoropolymer preferably comprise fromabout 0% to about 40% by weight, and more preferably from about 20% toabout 40% by weight of the ticks 14 on a solids basis. The fluoropolymerhelps to stabilize the tick 14 formulation such that the portion of thetick markings which remains on the transfer layer 12 presents a moreuniform surface.

The pigment particles within the ticks 14 may be of any color and eitherorganic or inorganic; however, it is preferred that the pigmentparticles in the tick layer 18 are dark in color. The dark pigments maybe used in combination with a white pigment such as titanium dioxide.White pigments may be added to the dark pigments in varied amounts toprovide a wider choice of color shading than is normally available fromcommercial dark pigments, thereby enhancing the different degrees ofcolor contrast achievable between the ticks 14 and the transfer layer12. Preferably the dark pigment is one such as carbon black or blackiron oxide. Solvent soluble dyes may be substituted for or used incombination with the pigment. The pigment particles are ground in a milluntil a preferred Hegman grind of 7 is attained, corresponding to about5 microns. The corresponding pigment particle size should preferably beno greater than 20 microns. Dispersed pigment particles, preferablycomprise from about 15% to about 30% by weight on a solids basis of theticks 14.

The wax component in the ticks 14 aids in the release of the carriersheet 16 and contributes to the low gloss level of the ticks 14. The waxis preferably a micronized wax and may be any micronized wax which has amelting point from about 82° C. to about 177° C. The wax should bedispersible to a particle size range of from about 1 to about 25microns, preferably from about 1 to about 10 microns. Other syntheticwaxes known to those skilled in the art may be substituted as long asthe molecular weight of the wax is high enough to form a solid atambient temperature so that the wax is dispersible without solubilizing.The dispersed wax particles preferably comprise from about 0% to about20% by weight on a solids basis and preferably from about 10% to about20% by weight on a solids basis of the ticks 14.

The carrier sheet 16 which is adhered to the ticks 14 may be, forexample, polyester, polyolefin or cellophane. Preferably, the carriersheet is a polyester. The polyester is preferably from about 75 to about92 gauge polyester and is biaxially oriented.

Typical preferred organic solvents useful for the formulations of thevarious layers of the present film 10 include acetone,methylethylketone, methylisobutylketone, ethanol, diacetone alcohol,isopropyl alcohol, ethylacetate, ethylbutyl acetate, methylpyrrolidone,cyclohexanone, glycol ethers, toluene and xylene. It is understood byone skilled in the art that the appropriate solvent should be chosenwith regard to its compatibility with those resins which are used in theformulations of the various layers of the film 10. Factors such asintended end use, type of carrier 16, resin solubility, potentialtoxicity, and boiling point should be considered in choosing anappropriate solvent.

The film 10 may further comprise various additives known to thoseskilled in the art including, among others, leveling agents, wettingagents, adhesion promoters, pigment stabilizers and dispersants. Suchadditives may be present throughout all layers of the film 10, and maycomprise up to about 2% of the film 10 on a solids basis.

The film 10 is preferably prepared by direct gravure application of thelayers of the film 10 to the carrier 16 by any typical gravureapparatus. The weight of the coatings is dependent primarily upon theparticular resins selected for the various layers of the film 10 and thequantity of pigmentation added to the film 10. The total coating weightgenerally ranges from about 30 to about 40 grams/square meter; however,in certain applications, the weight may be as high as 80 grams/squaremeter or as low as 5 grams/square meter.

The invention will now be described in more detail with respect to thefollowing specific, non-limiting examples:

EXAMPLE I

A tick formulation was prepared by mixing all of the components in theweight percentages listed in Table 1, below, with the exception of thewax, the polyvinyl fluoride and the catalyst in a jacketed vessel havingcooling water circulating through the jacket for temperature control.Throughout the procedure for preparation of the tick formulation, thetemperature of the components should be kept below about 38° C. at alltimes to prevent gelation.

                  TABLE I    ______________________________________                        Weight Percentage    Component in Tick Formulation                        (%)    ______________________________________    Cyclohexanone       23.6    Methylisobutylketone                        20.4    Ethyl Alcohol       5.2    Polyvinyl Terpolymer                        10.0    (3% OH Groups) (Tg = 53° C.)    Hexamethoxymethyl Melamine                        8.0    (Specific Gravity = 1.2)    Polymethylmethacrylate                        2.0    (Tg = 86° C.) (Specific    Gravity = 1.17)    Amide Wax           7.0    (Drop Point = 141° C.)    (Acid Number ≦ 10)    Polyvinylidene Flouride                        12.0    (Specific Gravity = 1.7)    Black Iron Oxide (pigment)                        11.0    Strong Acid Catalyst                        0.8    ______________________________________

The mixture is then milled or ground. The polyvinylidene fluoride andwax are dispersed independently and separately from the components inthe vessel, and added to the ground mixture in the jacketed mixingvessel and mixed at low-shear rates. Immediately before application ofthe tick formulation to the carrier sheet by gravure roller, the acidcatalyst was added to the formulation. The tick layer was applied to apolyester film carrier sheet having a matte gloss level.

A protective layer formulation was prepared and contained theingredients in the weight percentages listed in Table II.

                  TABLE II    ______________________________________                           Weight Percentage    Protective Release Layer Components                           (%)    ______________________________________    Methylethylketone      26    Polymethylmethacrylate 37    (non-reactive acrylic)    (Tg = 105° C.) (Specific Gravity = 1.17)    Polyethylene Wax       11    (23% Oxygen) (Melting Point = 140° C.)    Toluol                 26    ______________________________________

The protective release layer formulation was applied by gravure rollerto the cured ticks already adhered to the carrier sheet, and cured atthe same temperature and in the same manner as the tick formulation. Aprint layer providing a wood-grain pattern was applied to the protectivelayer by gravure roller and cured. The composition of the print layer isshown in Table III.

                  TABLE III    ______________________________________                          Weight Percentage    Grain Ink Component   (%)    ______________________________________    Toluol                37.8    Methylisobutylketone  37.8    Butyl acetate         8.4    Polyvinyl Chloride Terpolymer                          13.4    (Tg = 72° C.) (Specific Gravity = 1.35)    Carbon Black          2.6    ______________________________________

A base coat having the components shown in Table IV and an adhesive coathaving the components shown in Table V with the respective weightpercentages were then consecutively applied to the print layer and curedin the same manner described above.

                  TABLE IV    ______________________________________    Base Coat Component                      Weight Percentage    ______________________________________    Toluol            28.9    Butyl Acetate     9.6    Ethyl Alcohol     0.5    Anionic Wetting Agent                      0.5    Polyester Adipate 5.3    Yellow Iron Oxide 20.7    Red Iron Oxide    7.0    Black Iron oxide  3.7    Polymethylmethacrylate                      22.6    (30% in toluene and butanol)    (Tg = 105° C.)    Polymethylmethacrylate                      1.2    (Tg = 86° C.)    (Specific Gravity = 1.17)    ______________________________________

                  TABLE V    ______________________________________    Adhesive Component   Weight Percentage    ______________________________________    Toluol               50.0    Methyl, n-butylmethacrylate                         50.0    Copolymer    (Tg = 80° C.) (Acid Number = 5)    ______________________________________

The finished film was hot-stamped onto a styrene substrate according totypical methods known to those skilled in the art, and the carrier filmwas removed. The film, upon removal of the carrier, exhibited a tickpattern having tick exhibiting a gloss level of 3%. The ticks werereadily distinguishable from the film at all viewing angles. The opticaleffect was perceived as an indentation and the additional color gave theticks the appearance of a realistic wood ticks. The film was alsoreadily overcoatable by a second piece of the same film.

I claim:
 1. A heat transferable film for affixation to a substrate to bedecorated, comprising:(a) a transfer layer having a first gloss leveland at least one color, the transfer layer affixable on the bottom to asubstrate; (b) a plurality of individual spaced-apart markings, themarkings comprising a soluble resin mixture, particles dispersed withinthe soluble resin mixture, and a catalyst for promoting and acceleratingcross-linking reactions between the soluble resin mixture and resinswithin the transfer layer and between the soluble resin mixture and acarrier sheet, the markings having a color different from the at leastone color within the transfer layer and a second gloss level, differentfrom the first gloss level, and the markings being adhered to the top ofthe transfer layer; and (c) the carrier sheet adhered to the top of thespaced-apart markings wherein upon application of heat and pressure tothe film and subsequent removal of the carrier sheet, the individualspaced-apart markings are split along a plane generally parallel to thatof the film, with a first portion of each marking remaining adhered tothe carrier sheet and a second portion of each marking remaining adheredto the transfer layer such that the second portion of each marking formsa pattern of said markings on the top of the transfer layer.
 2. Theheat-transferable film according to claim 1, wherein the first glosslevel is at least 3% greater than the second gloss level.
 3. Theheat-transferable film according to claim 1, wherein the second glosslevel is from about 1.5% to about 8% as measured by a Gardner 60° glossmeter.
 4. The heat-transferable film according to claim 1, wherein thetransfer layer comprises:(a) a heat-activatable adhesive layer foraffixing the bottom of the transfer layer to a substrate; (b) a basecoat adhered to the top of the heat-activatable adhesive layer; (c) atleast one print layer comprising an ink pattern adhered to the top ofthe base coat; and (d) a protective release layer covering and adheredto the top of said at least one print layer, said protective releaselayer comprising a lacquer-based coat, wherein the individualspaced-apart markings are adhered to the top of the protective releaselayer.
 5. The heat-transferable film according to claim 4, wherein thetransfer layer comprises from 1 to about 5 grain print layers.
 6. Theheat-transferable film according to claim 4, wherein the protectivelayer is a thermoplastic lacquer comprising a non-reactive resin.
 7. Theheat-transferable film according to claim 6, wherein the protectiverelease layer comprises, on a solids basis, from about 45% to about 85%by weight of a non-reactive thermoplastic resin, from about 2% to about10% by weight of a slip agent, from about 0.5% to about 5.0% by weightvinyl ethylacetate.
 8. The heat-transferable film according to claim 7,wherein the non-reactive resin is selected from the group consisting ofhomopolymers, copolymers and terpolymers of polymethylmethacrylate,polybutyl acrylate, polymethylacrylate, polyethylacrylate and mixturesthereof.
 9. A heat transferable film for affixation to a substrate to bedecorated, comprising:(a) a transfer layer having a first gloss leveland at least one color, the transfer layer affixable on the bottom to asubstrate; (b) a plurality of individual spaced-apart markings, themarkings comprising a soluble resin mixture comprising a reactive resinand a non-reactive resin, particles of wax, pigment, and fluoropolymerdispersed within the soluble resin mixture, and a catalyst for promotingand accelerating cross-linking reactions between the soluble resinmixture and resins within the transfer layer and between the solubleresin mixture and a carrier sheet, the markings having a color differentfrom the at least one color within the transfer layer and a second glosslevel, different from the first gloss level, and the markings beingadhered to the top of the transfer layer; and (c) the carrier sheetadhered to the top of the spaced-apart markings wherein upon applicationof heat and pressure to the film and subsequent removal of the carriersheet, the individual spaced-apart markings are split along a planegenerally parallel to that of the film, with a first portion of eachmarking remaining adhered to the carrier sheet and a second portion ofeach marking remaining adhered to the transfer layer such that thesecond portion of each marking forms a pattern of said markings on thetop of the transfer layer.
 10. The heat-transferable film according toclaim 9, wherein the particle size of the dispersed particles offluoropolymer is from about 0.2 to about 5 microns.
 11. Theheat-transferable film according to claim 9, wherein the fluoropolymeris selected from the group consisting of homopolymers, copolymers andterpolymers of polyvinylidene fluoride, polyvinyl fluoride,polyvinylidene chloride, polyvinyl chloride,polychlorotrifluoroethylene; copolymers of tetrafluoroethylene andhexafluoropropylene; and copolymers of vinylidene fluoride andhexafluoropropylene.
 12. The heat-transferable film according to claim9, wherein the fluoropolymer comprises a polyvinylidene fluoridehomopolymer.
 13. The heat-transferable film according to claim 9,wherein the individual spaced-apart markings comprise, on a solidsbasis, from about 11% to about 30% by weight soluble resin mixture, fromabout 0% to about 20% by weight wax particles, from about 15% to about30% by weight pigment particles, from about 0% to about 40% by weightfluoropolymer particles, said particles of wax, pigment andfluoropolymer dispersed within said soluble resin mixture, and fromabout 0.5% to about 1% by weight catalyst for promoting and acceleratingcross-linking reactions between the soluble resin mixture and resinswithin the transfer layer and between the soluble resin mixture and thecarrier sheet.
 14. The heat-transferable film according to claim 9,wherein the pigment is selected from the group consisting of carbonblack and iron oxide.
 15. The heat-transferable film according to claim9, wherein the particle size of the dispersed particles of pigment is nogreater than about 20 microns.
 16. The heat-transferable film accordingto claim 9, wherein the wax is a micronized wax having a particle sizeof from about 1 to about 25 microns.
 17. The heat-transferable filmaccording to claim 9, wherein the wax has a melting point of from about82° C. to about 177° C.
 18. The heat-transferable film according toclaim 9, wherein the reactive resins are selected from the groupconsisting of acrylic copolymers and terpolymers, vinyl copolymers andterpolymers, melamine, urea formaldehyde and mixtures thereof.
 19. Theheat-transferable film according to claim 9, wherein the non-reactiveresins are selected from the group consisting of homopolymers,copolymers and terpolymers of polymethylmethacrylate, polybutylacrylate, polymethylacrylate, polyethylacrylate and mixtures thereof.20. The heat-transferable film according to claim 1, wherein the carriersheet comprises a polymer selected from the group consisting ofpolyester, polyolefin and cellophane.